advanced engineering & technology consulting firm...optimization, finite element analysis,...

453 Kinns Road Clifton Park New York 12065 US Ph: (518) 312-1466 www.endeavos.com

ENDEAVOS Innovations Inc. Engineering Design Analysis Validation Optimization Simulation

Advanced Engineering & Technology Consulting Firm


Company Overview & Services

Endeavos Innovations is a comprehensive product development, research and engineering services company. Our core philosophy is creativity through collaboration. We work with startups, academia and large companies as part of their team to help innovation through engineering. We utilize state of the art methods and tools combined with years of experience to move an initial idea through various phases of technology development to market in the least amount of time and cost. Our services can also be employed at any phase of development or for any engineering or consulting need.

• Clifton Park, New York, USA.

• Established 2014.

• Technology Development & Engineering.

Design System Modeling Analysis (CAE) Test Rigs & Testing Clifton Park, NY Office


Engineering Team

Dr. Murat Ozmusul, Ph.D, (Principal Consultant) Gerald Reidenbaugh, (Mechanical Design Engineer)

Dr. Zaeem Khan, Ph.D, (Founder & President)

Dr. Khan is responsible for managing the operations of Endeavos Innovations Inc. He has over 22 years experience performing and supervising engineering analysis. He has previously held R&D position at GE Global Research where he worked on a variety of engineering projects ranging from bio-medical devices to wind turbines. His expertise includes: modeling and simulation of structures and dynamical systems involving Multiphysics (aero, structural, & thermal), design optimization, finite element analysis, conceptual and detailed design.

Yahya Doğu, Ph.D. (Principal CFD Consultant)

Dr. Yahya Doğu has over 20 years of experience in design and analysis of industrial applications of thermal-fluid systems and has been involved in many R&D projects. His expertise is built on fundamental sciences of fluid mechanics, heat transfer and thermodynamics and validating that with CFD simulations. His experience involves many specific areas: sealing in turbo machinery (brush seal, labyrinth seal, honeycomb seal, cloth seal), flow in porous media, water turbines, solar collectors, optical fiber drawing process, thermal analysis of metal cutting process, 3-D in-cylinder combustion modeling for internal combustion engine, heat exchangers, etc. He has filed two patents on brush seals at GE-CRD and authored many journal and conference papers.

Dr. Murat is a senior consultant. He is a mechanical engineer with more than 23 years of experience in the R&D industry. His expertise is in brush seals, steam turbines and mechanical design of test rigs. He was formerly a co-founder of SDM research and engineering based in Turkey and the founder of Pro-Solutions US engineering company. He has several high profile projects under his belt including multiple patents.

Jay Reidenbaugh has over 26 years of mechanical design and manufacturing experience. He has expertise in new concept development, design, analysis, project management, scheduling, estimating, simulation and optimization. He is a great team player with excellent problem-solving, time management, and organizational abilities when faced with complex multi-disciplinary engineering projects.


How We Do it…

• One stop resource for all mechanical engineering services

• State of the art CAE tools & engineering expertise.

• Expertise is provided when needed. This cuts overhead costs.

• Low rates for pre-seed, seed and early stage startups.

• Valuable resource on standby for established companies.

Results & Benefits

Market

Need

Conceptual

Design

Analysis &

Optimization

Detailed

Final Design

Physical

Prototyping

Testing

Explore all potential options to meet requirements.

Concepts evaluated via high fidelity simulations.

Down select concept is thoroughly evaluated & optimized for performance.

Prototypes developed for testing

Setup test rigs, instrumentation & controls for prototype testing.

Field Testing


Engineering Design

• Engineering design involves conceptual design based on simple first order engineering calculations. This process enables initial material selection, size and performance estimation.

• Based on this CAD (computer aid design) of initial concept is generated.

• This service also includes generation of engineering drawings for machining from provided CAD models as well as creation of CAD models from engineering drawings.

• Physical models are created using rapid prototyping tools such as 3D printing, desktop CNC machining as well as laser cut cardboard and foam.


Computer Aided Engineering (CAE)

Advanced simulations based on numerical computations such as finite element method (FEM) and computational fluid dynamics (CFD) is an essential part of product development process and detailed analysis of existing designs. This capability enables virtual prototyping and testing which significantly cuts down product development time and cost.

• Structural stress (Elastic/Plastic)

• Joints: Bolted, Adhesive (bonded), Welded, Riveted.

• Nonlinear Plasticity & Buckling.

• Fatigue Analysis

• Dynamics: Transient, Rigid Body, Explicit.

• Mechanical Vibrations (Modal, Harmonic, and Random Vibration Analysis.

• Rotor Dynamics.

• Composite Structures.


Finite Element Analysis (FEA)

• Structural stress (Elastic/Plastic)

• Nonlinear Plasticity & Buckling.

• Fatigue Analysis.

Gasket Analysis

Seal & Leakage Analysis

• Steady-State & Transient Thermal Analysis.

• Coupled Thermal & Structural Analysis


Finite Element Analysis (FEA)

Joints: Bolted, Adhesive (bonded), Welded, Riveted.

• Dynamics: Transient, Rigid Body, Explicit.

• Rotor Dynamics.

• Mechanical Vibrations (Modal, Harmonic, and Random Vibration Analysis.


Structural Topology Optimization

We have the capability to optimize structural designs to reduce mass, deflections as well as change structural stiffness to improve mechanical vibration behavior. Various tools and methods are utilized such as topology and shape optimization. Additionally, any aspect of thermal-structural performance can also be optimized.


Composite Material Structures

Fiber

Matrix

Composite Macro-Scale Analysis

Composite Meso-Scale (Laminate Analysis

Micro Mechanical Analysis


Analytical Spread Sheet & FEA Tools

We provide full spectrum of numerical simulations, however, not every aspect of real world physics can or should be modeled and numerically computed. On the other hand, physical experiments using test rigs might be needed. In some cases, simple analytical spread sheet models are sufficient for quick design assessment, concept evaluation etc. • We have developed in house analytical

tools for analysis such as bolted joints, gaskets and flanges based on current and established design and analysis methods.

• We also have the capability to link spread sheet tools with finite element analysis using ANSYS APDL. This standardizes analysis and removes any dependence on user skill level. All post processing can be automated.

• Based on your product development needs, we can custom build simple analytical spreadsheet tools for your organization.

Parameter Value Unit Description

d 0.750 in Bolt Nominal Diameter

TPI 16.00 - threads per inch

Lc 1.50 in Clamped Length

Lb 2.5 in Bolt length

Eb 30E+06 psi Young's Modulus Bolt Material

Sy 3.60E+04 psi Bolt Yield Strength

K 0.2 Bolt Torque Constant

p 0.0625 in Thread Pitch

dm 0.6688 in minor bolt dia

dp 0.7094 in bolt pitch dia

dt 0.6891 in Tensile Dia, Used in FEA

At 0.3730 in^2 Tensile Area "At"

Ab 0.4418 in^2 Nominal cross section area of bolt

Lthd 1.75 in Thread length upto 6" bolts

Ls 0.75 in Bolt Shank length

Lt 0.75 in Thread length in grip

kb 8.089E+06 lb/in Bolt Stiffness

Sp 3.06E+04 psi Proof Load

Fi 2.70E+04 lbf Bolt Preload based on 0.75*Sp

T 337.5 ft-lb Bolt Torque Constant

Parameter Value Unit Description

Gasket Type 1 - Confined (0) or unconfined (1)

Dpv 4 psi Internal Dia of Pr Vessel

Df 7.25 in Outside Flange Dia

Dbc 5.5 in Bolt Circle Diameter

Pr 1500 psi Internal pressure

t 0.125 in Gasket Thickness

nb 8 - No of bolts around flange

Eg 1.000E+04 psi Young's Modulus Gasket Material

Ag 3.4790 in^2 Gasket contact Area per Bolt

km 1.05E+07 lb/in Joint Member Stiffness

kg 1.088E+07 lb/in Gasket Stiffness

kmc 5.346E+06 lb/in Combined member Stiffness

C 0.602 - Joint Stiffness Ratio

P_total 695 lbf Total Force on End Cap of Pr vessel

P 29 lbf Applied force per bolted Joint

Pb 17 lbf Portion of Fa felt by bolt

Pm 11 lbf Portion of Fa felt by Member

Fb 27017 lbf Resultant Bolt Load

Gasket Design for Pressure Vessel

Bolt Analysis (UNC)

Spread Sheet Tool

ANSYS FEA APDL Tool


Computational Fluid Dynamics (CFD)

• Air, ground and sea vehicle lift and Drag.

• Thermal-Fluid systems

• Seals for gas/steam turbine (brush seal, labyrinth seal, honeycomb seal, cloth seal)

• Flow in porous media

• In-cylinder combustion for internal combustion engine

• Hydro, wind turbines

• Heat exchangers

Internal Combustion Engine


Computational Fluid Dynamics (CFD)

Combustion

Turbo Machinery HC: 3.175 mm (1/8’’)

Düz Stator

HC: 0.793 mm (1/32’’)

HC: 1.590 mm (1/16’’)


System Models

• Multi-Domain Lumped Parameter Models based on Matlab & Simulink platforms.

• Simulate effects of dynamic loads on structures e.g. wind, seismic, ocean wave loads.

• System design & performance optimization.


Robust Design and Design Optimization


Test Rig Design, Instrumentation & Controls

Development of Complete Test Rigs


Engineering Software & Hardware Tools

Desktop CNC

3D Printing

High Performance Computing:

Xeon Gold 6130, 16 core CPU with 128 GB RAM with SSD storage.

Software Tools:

• SolidWorks (CAD/CAM)

• ANSYS (FEA & CFD)

• Matlab (System Models)

• NI LabVIEW (Test Rig instrumentation)


Machining & Rapid Prototyping

Sanken Industry Co., Ltd.

Resin Resin (Transparency)

Resin (Lathe)

Metal

Metal (Lathe)

Gears

Sheet Metal & Bending Bending

We work closely with Sanken Industry based in Japan for development of prototypes for testing. Sanken offers highest quality of machined components based on their unique in house technology with fast turn around times.

advanced engineering & technology consulting firm...optimization, finite element analysis,...

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